Surfboard and method of manufacturing

ABSTRACT

A surfboard includes a core covered with a laminate and having perforations where the user places his feet, in order to prevent air blisters from forming between the core and laminate. The core is formed from an extruded closed-cell polystyrene foam block which has been shaped by restraining it against a shaped form using shaped restraining tools and straps, and heating it; and by cutting using a hot wire. The core is laminated with FIBERGLAS® and epoxy resin, and the perforations are formed using a perforating tool that has a planar or curved working surface and one or more heated needles extending perpendicularly from the working surface.

FIELD OF THE INVENTION

[0001] The present invention relates generally to water sportsequipment. The present invention relates more particularly, though notexclusively, to a water sports board made of laminated closed-cell foamwith perforation vents in the laminate for preventing deformations ofthe surface of the board. The present invention is useful forsurfboards, sailboards, wave skis and other applications requiringbuoyant, rigid, and durable boards.

BACKGROUND OF THE INVENTION

[0002] Many water sports boards and craft (e.g., surfboards, sailboards,wave skis, etc.) are made of expanded open-cell rigid polymer foam.Where the discussion herein refers to a surfboard or “board”, it appliesto surfboards, sailboards, body boards, wave skis, and other types ofwater sports boards and craft as well. To make a board of open-cellfoam, a “molded method” is often used. Specifically, in using the moldedmethod, a mold of the board is filled with liquid foam, which expands tofill the mold. The foam is then allowed to harden in the mold until itis rigid. The rigid foam is made of air cells that are open to eachother. The cells at the surface of the rigid foam are also open to theatmosphere. Another method of board formation is the traditionalhand-shaping method wherein the board is cut, or shaped, from a block ofexpanded foam.

[0003] A problem with open-cell foam is that it absorbs water. Tominimize this absorption of water, the open-cell foam is often coatedwith a water-proofing material, such as FIBERGLAS® and epoxy resin, toseal the board and make the board more durable.

[0004] Unfortunately, even though covered with a water-proofingmaterial, in the event the board is bumped or the water-proofingmaterials are breached, the board absorbs water through that breach.When the open-cell foam has absorbed water, the open-cell foam is muchheavier than when it is dry. A board made with open-cell foam that hasabsorbed water is significantly more difficult to use because of itsincreased weight and decreased buoyancy. Furthermore, a board that hasabsorbed water must be dried out before it is stored, in order to avoiddeterioration of the board.

[0005] In light of the above, it would be advantageous to make a boardhaving similar buoyancy, rigidity, and durability characteristics of aboard made from open-cell foam, yet does not absorb water into the foammaterial if the water-proofing material is breached.

SUMMARY OF THE INVENTION

[0006] The advantages of open-cell foam can be obtained, and itsdisadvantages avoided, by using a closed-cell foam in its place.Closed-cell foam is extruded, and then formed into the shape of a boardby hand shaping by a professional board shaper, or by using CNCmachining into the desired board shape, instead of expansion into a moldas is the process used with open-cell foam. In a preferred embodiment,closed-cell foam may be made of polystyrene. An advantage of closed-cellfoam is that it does not substantially absorb water. A board made ofclosed-cell foam does not become substantially heavier due to waterabsorption, and retains its physical properties, including buoyancy andease of use for water sports and other purposes. Closed-cell foam alsodries out much more quickly than open-cell foam, without yellowing ordamage areas.

[0007] The present invention includes a surfboard made of laminatedclosed-cell foam. The laminate is perforated at places where pressure islikely to be applied to the surface of the board (e.g., where a user islikely to stand), such that air, or gas, can escape from between thelaminate and foam. This avoids the formation of air blisters, thusovercoming a disadvantage to the use of laminated closed-cell foam.

[0008] Closed-cell foam extruded into a rough board shape may bereferred to as a “blank” or “block”. The blank may be heated, pressedand cut into a desired shape. The shaped blank may be laminated withwater-proofing materials, such as FIBERGLAS® and epoxy resins, to makethe board more durable.

[0009] To make a board of the present invention, a blank is treated withheat and pressure to shape it, if desired, and to anneal the surface(close any open cells). The board is shaped by placing the blank againsta shaped form, pressing the blank against the form by use of tensiondevices (e.g., restraining tools and straps), heating the blank usingheated water vapor, then cooling it until it holds its new shape. Theheated and pressed blank may be further shaped by cutting it with a hotwire. The cut and shaped blank or “core” is laminated with FIBERGLAS®and epoxy resin. Once laminated, the laminate is perforated in multiplelocations using a tool that has a substantially planar or curved surfacewith multiple perforation needles extending therefrom. The perforationsare formed by pressing or rolling the needled surface of the toolagainst the laminate thereby penetrating the laminate. The board mayhave one or more optional fins.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The novel features of this invention, as well as the inventionitself, both as to its structure and its operation, will be bestunderstood from the accompanying drawings, taken in conjunction with theaccompanying description, in which similar reference characters refer tosimilar parts, and in which:

[0011]FIG. 1 is a perspective view of the Improved Surfboard And MethodOf Manufacturing of the present invention, showing a finished board;

[0012]FIG. 2A is a side view of the Improved Surfboard And Method OfManufacturing of the present invention, showing how a blank is curved byrestraining it against a form with restraining tools and straps, andsubjected to a heat source;

[0013]FIG. 2B is an exploded side view of the Improved Surfboard AndMethod Of Manufacturing of the present invention, showing how multipleblanks are simultaneously curved by stacking them vertically, separatedby a flexible metal heat-conducting sheet, and restraining the stackagainst a form with restraining tools and straps, and subjecting thestack to a heat source;

[0014]FIG. 2C is a side view of the Improved Surfboard And Method OfManufacturing of the present invention, showing how multiple blanks aresimultaneously curved by stacking them vertically, separated by a metalflexible heat-conducting sheet, and restraining the stack against a formwith restraining tools and straps, and subjecting the stack to a heatsource;

[0015]FIG. 3 is a top view of the Improved Surfboard And Method OfManufacturing of the present invention, showing how the blank is cutinto a surfboard shape using a hot wire;

[0016]FIG. 4 is a perspective view of the Improved Surfboard And MethodOf Manufacturing of the present invention, showing a cut-away view ofthe interior of the board and showing how blisters are formed in thesurface of the board without perforations formed in the laminate;

[0017]FIG. 5 is a cross-sectional view of the Improved Surfboard AndMethod Of Manufacturing of the present invention, taken across line 5-5of FIG. 4, showing an air, or gas, blister;

[0018]FIG. 6 is a top view of the Improved Surfboard And Method OfManufacturing of the present invention, showing how perforations formedin the laminate by a perforation tool, prevent formation of blisters byallowing any air or gas to escape through the perforation;

[0019]FIG. 7 is a top view of the Improved Surfboard And Method OfManufacturing of the present invention, showing a pattern ofperforations in the surface of a short board;

[0020]FIG. 8 is a top view of the Improved Surfboard And Method OfManufacturing of the present invention, showing a pattern ofperforations in the surface of a long board;

[0021]FIG. 9 is a side view of the Improved Surfboard And Method OfManufacturing of the present invention, showing a perforating toolhaving a substantially planar working surface, and a number ofperforating needles extending perpendicularly from the planar workingsurface;

[0022]FIG. 10 is a side view of the Improved Surfboard And Method OfManufacturing of the present invention, showing a perforating toolhaving a curved working surface and a number of perforating needlesextending perpendicularly from the curved working surface;

[0023]FIG. 11 is a side view of the Improved Surfboard And Method OfManufacturing of the present invention, showing a cross-section of aboard with a curved perforating tool perforating the laminate of theboard; and

[0024]FIG. 12 is a flow chart representing an exemplary process of thepresent invention for manufacturing the Improved Surfboard of thepresent invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0025] A preferred embodiment of the Improved Surfboard And Method OfManufacturing of the present invention is shown in FIG. 1 and isgenerally designated 100. Board 100 has a foam core 1 10 (shown in FIG.4), a laminate 120 covering core 110 having a stringer 122, and isformed with a number of perforations 130 in laminate 120. Core 110 ofboard 100 is formed by shaping a “blank”. A blank is a substantiallyrectangular block of closed-cell foam.

[0026] Board 100 may have one or more optional fins 160. Board 100 shownin FIG. 1 is in the style of a short board. Perforations 130 are shownplaced where a user would place his or her feet on board 100.Perforations 130 may alternatively be placed elsewhere on board 100.

[0027] Referring to FIG. 2A, an apparatus for shaping a blank is shownand generally designated 200. FIG. 2A shows a blank (or foam body orblock) 210. Blank 210 may be made of closed-cell extruded polystyrenefoam. Such a blank 210 is made by extruding closed-cell polystyrene foaminto a foam body of the desired shape. Blank 210 may alternatively bemade of other materials having strength similar to closed-cell foam.

[0028]FIG. 2 shows two positions for blank 210, an initial position 230(shown in dashed lines) and a shaped position 240. FIG. 2 also shows aform (or form tool or mold) 250 having a shaped form surface 254. Shapedform surface 254 has a shape in which blank 210 is desired to be shaped.FIG. 2 also shows restraining tools 260 each having a restraining toolsurface 264 corresponding to shaped form surface 254 in the manner inwhich blank 210 is desired to be shaped. Straps 270 extend from form 250to tools 260 and are tightened to bring tools 260 toward form 250 tocapture blank 210 between the tools 260 and the form 250.

[0029] Blank 210 may be shaped in the following manner. Blank 210 isinitially placed in initial position 230 (shown in dashed lines) uponshaped form surface 254 of form 250. Restraining tool surface 264 ofeach restraining tool 260 is placed upon blank 210. Straps 270 areattached to restraining tools 260 and to form 250. Tension is applied tostraps 270 such that each restraining tool surface 264 is pressedagainst blank 210, and blank 210 is pulled toward and pressed againstshaped form surface 254 of tool 250. At the same time, heat may beapplied to blank 210 from heat source 272.

[0030] The application of heat and tension to blank 210 causes blank 210to be conformed to shaped form surface 254 of form 250 and torestraining tool surfaces 264. In a preferred embodiment, the heatprovided by heat source 272 may not exceed 180 degrees Fahrenheit, andfor an exposure period of less than 30 minutes. Outside temperaturevariations and humidity may affect the heat levels and duration appliedto form the blank 210. Other heating periods and temperatures may beused, however, without departing from the present invention. Rather, thespecific temperature and time periods are merely exemplary of apreferred embodiment, and no limitation is intended.

[0031] Once heated, blank 210 is then allowed to cool until it holds theshape of shaped form surface 254 of form 250 and restraining toolsurfaces 264 in shaped position 240 without being pressed against shapedform surface 254 or restraining tool surfaces 264. Restraining tools 260and straps 270 are then removed from blank 210, and blank 210 is removedfrom form 250. Form 250 and restraining tools 260 are made of one ormore materials that can withstand pressure and heat required to shapeblank 210. In a preferred embodiment, form 250 may be made from wood ormetal, and restraining tools 260 may be made from wood or metal,however, other materials having suitable strength and resistance tomoisture may be used.

[0032] While two tools 260 have been shown in FIG. 2A, it is to beappreciated that any number of tools may be used without departing fromthe present invention. Additionally, tool 260 may extend the length ofform 250 such that a single tool 260 is used to capture the entire blank210.

[0033] Referring now to FIG. 2B, an exploded side view of the ImprovedSurfboard And Method Of Manufacturing of the present invention is shownand generally designated 280. In apparatus 280, multiple blanks 210 thatare substantially rectangular blocks, are vertically stacked together,separated by a flexible metal heat-conducting sheet 274. The stack ofblanks 210 and sheets 274 are positioned over form 250.

[0034] Once in position, restraining straps 270 are attached to tools260 and the straps 270 are tightened such that the stack of blanks 210and sheets 274 are brought tightly against form 250. As the straps 270are tightened, the blanks 210 and sheets 274 are deformed to match thecurvature of tools surfaces 264 and form 250. When the blanks 210 are inthe proper form against form 250, heat is supplied by heat source 272for a predetermined period of time. At the end of that heating timeperiod, the heat source is removed, and the straps are removed, yieldingseveral blanks 210 having the curvature of curved surface 254 of form250.

[0035] Flexible metal heat-conducting sheet 274, in a preferredembodiment, is made from aluminum, however, it is to be appreciated thatother materials having similar flexibility and heat transfercharacteristics may be used. The sheet 274 provides for separationbetween blanks 210 as well as conducts heat from heat source 272. Theconduction of heat between blanks 210 is important because blanks 210,by their nature, are good heat insulators. By providing a heatconduction path between blanks 210 in the stacked configuration, eachblank is exposed to sufficient heat across its entire surface during theheating period to provide for the formation of blank 210 into the curvedform 240 (shown in FIG. 2A).

[0036] Referring now to FIG. 2C, a side view of the Improved SurfboardAnd Method Of Manufacturing of the present invention 280 is shown. Thisfigure depicts the process by which multiple blanks 210 aresimultaneously curved by stacking them vertically, separated by a metalflexible heat-conducting sheet 274, and restraining the stack against aform 250 with restraining tools 260 and straps 270. Once blanks 210 arein the proper position against curve 254 of form 250, the entire stackof blanks 210 and sheets 274 is subjecting to a heat from heat source272, such as steam.

[0037]FIG. 3 shows a configuration for cutting blank 210 into a desiredshape, generally designated 300. More specifically, FIG. 3 shows blank210 with portions 310 cut away from blank 210 to shape a nose of a boardof the present invention. In a preferred embodiment, cut 310 is formedby a hot wire (not shown in FIG. 3) that is known in the art. FIG. 3shows cut 310 as being in a surfboard shape. Blank 210 may also beshaped by various methods including, without limitation, furtherheating, further pressing, further cutting, sanding, grinding,smoothing, and other shaping techniques known in the art. After blank210 has been finally shaped, it may be referred to as a core 110 asdiscussed in conjunction with FIG. 1.

[0038] Referring now to FIG. 4, a cut-away view of board 100 is shownand reveals core 110 having a stringer 122. Stringer 122 is typicallymade of wood, extends the length of core 110 and provides stiffening tothe board 100. After core 110 has been formed, it is covered with asealing material, such as FIBERGLAS® and epoxy resin, which formlaminate 120. This sealing material makes board 100 more durable, andprovides a water-proof covering. FIG. 4 also shows bubbles, or blisters,410 caused by air, or gas, pockets 420 that can form between core 110and laminate 120 following use of the board.

[0039] Referring to FIG. 5, a cross-sectional view of board 100 takenacross line 5-5 of FIG. 4 is shown. Specifically, FIG. 5 shows airblister or bubble 410 caused by air pocket 420 between core 110 andlaminate 120. For instance, when a user stands on board 100, thepressure of his feet upon board 100 can cause localized deformation tothe foam at that place. This deformation causes air pockets 420 to formbetween core 110 and laminate 120 in that location. Each air pocket 420causes the area of laminate 120 adjacent to air pocket 420 to be raisedaway from core 110, causing a raised area or “blister” 410 in laminate120.

[0040] Air blisters 410 may form where the user places his feet on board100, however, blisters 410 can also be caused by other sources ofpressure upon board 100 at other places on board 100. Each air blister410 causes a deformation of laminate 120, which can damage laminate 120and decrease the strength of board 100 and make it more difficult touse. Additionally, exposure of the board 100 to heat sources, such asthe sun, may cause the formation of air blisters 410 between the core110 and the laminate 120 when the board is not properly vented.

[0041]FIG. 6 shows another cross-sectional view of board 100 similar toFIG. 5, but with at least one perforation vent 130 now formed inlaminate 120 to allow air in air pocket 420 to escape, thus reducing thesize of air pocket 420 and in turn reducing or eliminating blister 410.The perforation vents 130 help avoid deformation and damage to laminate120, and helps maintain the utility of board 100. Each perforation vent130 is large enough to allow air to pass through it, and small enough toallow little water or no water to pass through it. Thus, eachperforation 130 allows air to get out from between laminate 120 and core110, but allows little water or no water to get in between laminate 120and core 110.

[0042] In a preferred embodiment, perforations 130 are formed throughlaminate 120 of board 100 at the time of manufacturing and prior to use,and thus, prior to the formation of any bubbles or blisters 420. As aresult, there is little or no chance for a blister to form, because anyair or gas that develops between laminate 120 and core 110 escapesthrough perforation 130 before it can develop into a blister 410.

[0043] As used herein, it is to be understood that “little water”comprises the meanings of “no water” and “substantially no water” aswell as the meaning of “a very small amount of water more than nowater.” No measurable or significant weight change is caused by anymoisture absorption into the surfboard or surf craft.

[0044] Each perforation vent 130 is formed by a perforating tool 610which has a perforating tool body 620 having a working surface 624, andat least one perforation needle 630 extending from working surface 624.Each perforation vent 130 is formed as follows. Working surface 624 isplaced adjacent laminate 120 and perforating tool 610 is manipulatedsuch that at least one needle 630 is translated in the direction 640toward board 100 until needle 630 penetrates (or perforates) laminate120 to form an airway, or vent 130, through the laminate 120.

[0045] Perforating tool 610 is then manipulated such that each at leastone needle 630 is then translated in the direction 650 opposite thedirection 640 in which needle 630 points, and needle 630 is withdrawnfrom laminate 120, leaving a perforation, or vent, 130 formed inlaminate 120 by each needle 630 that penetrates laminate 120. In apreferred embodiment of the present invention, each needle 630 does notpenetrate core 110. In an alternative embodiment of the presentinvention, at least one needle 630 at least partially penetrates core110.

[0046] Needles 630 may be made of stainless steel. Needles 630 mayalternatively be made of any other material having sufficient strengthto perforate laminate 120. In a preferred embodiment of the presentinvention, at least one needle 630 is heated to facilitate penetrationof laminate 120. If needles 630 are heated, they may be heated to arange of 200 to 250 degrees F. Alternatively, needles 630 may be heatedto a temperature in the range from zero degrees Kelvin to the meltingpoint temperature of the material of which the needles 360 are made. Inan alternative embodiment of the present invention, each needle 630 isnot heated.

[0047] In an alternative embodiment, needles 630 may be formed withgrooves or threads 635 like a traditional drill bit having a smalldiameter. In such an embodiment, perforating tool 610 may be capable ofrotating needle 630 in direction 633 to bore a perforation vent 130through laminate 120.

[0048]FIG. 7 is a top view of board 100. Board 100 shown in FIG. 7 is ashort board. An array of perforations 130 are placed where a user wouldlikely place his or her feet on board 100. Perforations 130 mayalternatively be placed in any other location on board 100, such as nextto the rails of the surfboard.

[0049] Referring now to FIG. 8, a top view of another embodiment of theImproved Surfboard And Method Of Manufacturing of the present inventionis shown and generally designated 800. This embodiment is a typical longboard and has perforations 130 in locations where a user is likely toplace his or her feet on this type of board 800. Perforations 130 mayalternatively be placed in any other location on board 800.

[0050]FIG. 9 is a side view of another embodiment of a perforating toolgenerally designated 910. Tool 910 includes a flat body 920 having aflat working surface 624 and multiple perforating needles 630. FIG. 9shows needles 630 as substantially parallel to each other, and extendingfrom working surface 624 at an angle substantially perpendicular toworking surface 624 at the point where needle 630 intersects workingsurface 624. In an alternative embodiment, each needle 630 may extendfrom working surface 624 at an angle other than perpendicular to workingsurface 624 at the point where needle 630 intersects working surface624.

[0051] Referring now to FIG. 10, a side view of another embodiment of aperforating tool is shown and generally designated 1010. Tool 1010includes a body 1020 having a curved working surface 1024 with a radius1012, and multiple perforation needles 630 extending radially away fromthe curved working surface 1024.

[0052]FIG. 10 shows each perforation needle 630 as being at an angle 632to body 1020. In a preferred embodiment, this angle 632 is ninetydegrees (90°) as dictated by its radial placement on the curved workingsurface 1024. FIG. 10 also shows each needle 630 as being substantiallyperpendicular to curved working surface 1024 at the point where needle630 intersects curved working surface 1024. In an alternativeembodiment, each needle 630 may be at an angle 632 other thanperpendicular to curved working surface 1024 at the point where needle630 intersects curved working surface 1024.

[0053] As shown in FIG. 10, each perforation needle 630 has a length 634and a diameter 636. In a preferred embodiment, length 634 is slightlylonger than the thickness 638 of laminate 120 (as shown in FIG. 6).Also, in a preferred embodiment, thickness 638 may be ⅛ to {fraction(3/16)} inch or more, and length 634 may be {fraction (3/16)} inch(0.1875″) or more, so long as the length 634 is equal to or greater thanthickness 638.

[0054] The diameter 636 of perforation needle 630 may vary between 0.005inches and 0.05 inches, and in a preferred embodiment, is 0.008 inches.It is to be appreciated that although perforation needle 630 has beendepicted in the Figures as a cylindrical needle, no limitation as to thecross-sectional shape is intended. To the contrary, the cross-sectionalshape of the perforation needle 630 may vary, including but not limitedto, oval, rectangular, square, or other shapes. Regardless of thecross-sectional shape of perforation needle 630, the cross-sectionalarea of vent 130 remains small enough to allow the exit of gassescollecting between material 120 and core 110.

[0055]FIG. 11 shows how curved perforating tool 1010 is used to make arow of perforations 130. FIG. 11 shows a cross section of a surfboard ofthe present invention, with curved perforating tool 1010 positionedadjacent board 100. In use, curved working surface 1024 is placedadjacent laminate 120 such that at least one needle 630 penetrateslaminate 120. Curved working surface 1024 is then “rolled” clockwise indirection 1030 across laminate 120 to a second position (shown by 1020′in dashed lines) such that each perforation needle 630 successivelypenetrates and is then withdrawn from laminate 120, leaving aperforation vent where each needle 630 has penetrated laminate 120. FIG.11 shows curved working surface 1024 as contacting laminate 120.

[0056] Alternatively, curved perforating tool 1010 can be manipulatedsuch that curved working surface 1024 does not actually contact laminate120 thereby avoiding any damage to laminate 120 from perforating tool1010. For instance, as curved perforating tool 1010 is rolled clockwiseabove laminate 120, each needle 630 rotates as the tool 1010 istranslated, such that each needle 630 remains substantiallyperpendicular to laminate 120 as it forms perforation vent 130. This isparticularly useful when tool 1010 is heated, and contact between tool1010 and laminate 120 may cause marks or blemishes to form.

[0057] In FIG. 11, curved working surface 1024 is curved in at least onedimension of curved working surface 1024. FIG. 11 shows curved workingsurface 1024 as substantially convex. Alternatively, curved workingsurface 1024 can be at least partially concave without departing fromthe present invention. In a preferred embodiment, the curve of curvedworking surface 1024 is substantially an arc of a circle that has aradius 1012, in at least one dimension of curved working surface 1024.Alternatively, curved working surface 1024 can have a curve that isother than circular, including, without limitation, parabolic,hyperbolic, or any combination thereof.

[0058] Referring now to FIG. 12, a flow chart representing a preferredmethod of manufacturing an Improved Surfboard of the present invention,and is generally designated 1200. Method 1200 includes a first step 1202in which one or more closed-cell foam blanks is obtained, and thenplaced on the form in step 1204. Once on the form, conductive sheets areinserted between the blanks in step 1206, and the blanks and conductivesheets are secured to the form using tools and straps in step 1208.

[0059] The assembly of tools, blanks separated by sheets, and secured tothe form, is then exposed to heat from a heat source for a predeterminedtime period in step 1210. At the expiration of that time period, theassembly is cooled for a second predetermined time period in step 1212.

[0060] Once cooled, the tools and straps are removed, and the blanks areremoved from the form and separated from the conductive sheets in step1214.

[0061] Once thoroughly cooled, the now-formed blanks are shaped to forma core and covered with sealing material in step 1216. Once the sealingmaterial is dry, a number of vents are formed through the sealingmaterial in final step 1218 to yield an Improved Surfboard of thepresent invention.

[0062] While the particular Improved Surfboard And Method OfManufacturing as herein shown and disclosed in detail is fully capableof obtaining the objects and providing the advantages herein beforestated, it is to be understood that it is merely illustrative of thepresently preferred embodiments of the invention and that no limitationsare intended to the details of construction or design herein shown otherthan as described in the appended claims.

I claim:
 1. A surfboard, comprising: a core; a laminate covering saidcore; and at least one perforation in said laminate.
 2. A surfboard asin claim 1, wherein: said laminate comprises FIBERGLAS® and epoxy resin.3. A surfboard as in claim 1, wherein: said at least one perforationallows air to pass through it, and said at least one perforation allowslittle water to pass through it.
 4. A surfboard as in claim 1, wherein:said core comprises closed-cell foam.
 5. A surfboard as in claim 4,wherein: said foam is extruded.
 6. A surfboard as in claim 4, wherein:said foam comprises polystyrene.
 7. A method of manufacturing asurfboard, comprising the steps of: providing a core covered by alaminate; and forming at least one perforation in said laminate.
 8. Amethod of manufacturing as in claim 7, wherein: said step of forming atleast one perforation in said laminate, comprises the steps of providinga perforating tool having a working surface and at least one needleextending from said working surface at an angle substantiallyperpendicular to said working surface at the point where said at leastone needle intersects said working surface; manipulating saidperforating tool such that said at least one needle is translatedsubstantially in the direction that said at least one needle points,such that said at least one needle penetrates said laminate; andmanipulating said perforating tool such that said at least one needle istranslated substantially opposite the direction that said at least oneneedle points, such that said at least one needle is withdrawn from saidlaminate.
 9. A method of manufacturing as in claim 8, wherein: said atleast one needle is heated.
 10. A method of manufacturing as in claim 8,wherein: said working surface is substantially planar.
 11. A method ofmanufacturing as in claim 7, wherein: said step of forming at least oneperforation in said laminate, comprises the steps of providing aperforating tool having a working surface curved in at least onedimension, and at least one needle extending from said working surfaceat an angle substantially perpendicular to said working surface at thepoint where said at least one needle intersects said working surface;rolling said working surface along said laminate such that each said atleast one needle successively penetrates and is then withdrawn from saidlaminate.
 12. A method of manufacturing as in claim 11, wherein: said atleast one needle is heated.
 13. A method of manufacturing as in claim 7,wherein: said step of forming at least one perforation in said laminate,comprises the steps of providing a perforating tool having a workingsurface having substantially the shape of an arc of a circle in at leastone dimension, and at least one needle extending from said workingsurface at an angle substantially perpendicular to said working surfaceat the point where said at least one needle intersects said workingsurface; rolling said working surface along said laminate such that eachsaid at least one needle successively penetrates and is then withdrawnfrom said laminate.
 14. A method of manufacturing as in claim 13,wherein: said at least one needle is heated.
 15. A method ofmanufacturing as in claim 7, wherein: said step of providing a corecovered by a laminate, comprises the steps of extruding closed-cell foaminto a blank; shaping said blank into a core; and covering said corewith a laminate.
 16. A method of manufacturing as in claim 1 5, wherein:said step of covering said core with a laminate, comprises the steps ofcovering said core with FIBERGLAS®; and covering said core with epoxyresin.
 17. A method of shaping a closed-cell foam blank, comprising thesteps of: providing a closed-cell foam blank; providing a form having ashaped form surface; providing one or more restraining tools, each saidone or more restraining tools having a restraining tool surface; placingsaid blank upon said shaped form surface; placing each said restrainingtool surface of said one or more restraining tools upon said blank;pressing said one or more restraining tools against said blank, whereinsaid blank is pressed against said shaped form surface; heating saidblank until said blank is conformed to said shaped form surface and toeach said restraining tool surface; and allowing said blank to cooluntil said blank remains so conformed without pressing said blankagainst said shaped form surface or each said restraining tool surface.18. The method of claim 17, wherein: said step of pressing said one ormore restraining tools against said blank, comprises the steps ofproviding one or more straps; attaching each of said one or more strapsto at least one of said one or more restraining tools and to said form;and applying tension to said one or more straps, wherein said blank ispressed against said shaped form surface.
 19. A method of perforating alaminate, comprising the steps of: providing a laminate; providing aperforating tool having at least one needle; and manipulating saidperforating tool such that said at least one needle perforates saidlaminate.
 20. A method as in claim 19, wherein: said at least one needleis heated.
 21. A method as in claim 19, wherein: said step of providinga perforating tool having at least one needle, comprises the step ofproviding a perforating tool having a working surface and at least oneneedle extending from said working surface at an angle substantiallyperpendicular to said working surface at the point where said at leastone needle intersects said working surface.
 22. A method as in claim 19,wherein: said step of manipulating said perforating tool such that saidat least one needle perforates said laminate, comprises the steps ofmanipulating said perforating tool such that said at least one needle istranslated in the direction that said at least one needle points, suchthat said at least one needle perforates said laminate; and manipulatingsaid perforating tool such that said at least one needle is translatedopposite the direction that said at least one needle points, such thatsaid at least one needle is withdrawn from said laminate.
 23. A methodas in claim 19, wherein: said step of forming at least one perforationin said laminate, comprises the steps of providing a perforating toolhaving a working surface having substantially the shape of an arc of acircle in at least one dimension, and at least one needle extending fromsaid working surface at an angle substantially perpendicular to saidworking surface at the point where said at least one needle intersectssaid working surface; rolling said working surface along said laminatesuch that each said at least one needle successively penetrates and isthen withdrawn from said laminate.
 24. A perforating tool, comprising: aperforating tool body having a working surface; and at least one needleextending from said working surface.
 25. A perforating tool as in claim24, wherein: said working surface is substantially planar.
 26. Aperforating tool as in claim 24, wherein: said working surface issubstantially curved in at least one dimension of said working surface.27. A perforating tool as in claim 24, wherein: said working surfacesubstantially has the shape of an arc of a circle in at least onedimension of said working surface.
 28. A perforating tool as in claim24, wherein: each said at least one needle is substantially parallel toeach other said at least one needle.
 29. A perforating tool as in claim24, wherein: each said at least one needle is substantially at an angleto each other said at least one needle.
 30. A perforating tool as inclaim 24, wherein: said at least one needle is substantiallyperpendicular to said working surface at the point where said at leastone needle extends from said working surface.
 31. A perforating tool asin claim 24, wherein: said at least one needle can be heated.